•••*****•*••••••
Disclosure to Promote the Right To Information
Whereas the Parliament of India has set out to provide a practical regime of right to
information for citizens to secure access to information under the control of public authorities,
in order to promote transparency and accountability in the working of every public authority,
and whereas the attached publication of the Bureau of Indian Standards is of particular interest
to the public, particularly disadvantaged communities and those engaged in the pursuit of
education and knowledge, the attached public safety standard is made available to promote the
timely dissemination of this information in an accurate manner to the public.
Mazdoor Kisan Shakti Sangathan
'The Right to Information, The Right to Live'
IS 7634-3 (2003) : Plastics Pipe Selection, Handling,
Storage and Installation for Potable Water Supplies - Code
of Practice : Part 3 - Laying and Jointing of UPVC Pipes
[CED 50: Plastic Piping System]
Jawaharlal Nehru
'Step Out From the Old to the New'
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[SS^ V I l>5ft>!>5^>«SV:
^^\\X^L
Satyanarayan Gangaram Pitroda
Invent a New India Using Knowledg
Bhartrhari — Nitisatakam
"Knowledge is such a treasure which cannot be stolen"
BLANK PAGE
<a^EL
!**>
PROTECTED BY COPYRIGHT
IS 7634 (Part 3) : 2003
HPT 3 ^ tf\ eft # qi^if[ c^t f^RT TJcj vjfl^HI
Indian Standard
PLASTICS PIPES SELECTION, HANDLING, STORAGE
AND INSTALLATION FOR POTABLE WATER
SUPPLIES — CODE OF PRACTICE
PART 3 LAYtNG AND JOINTING OF UPVC PIPES
( First Revision )
ICS83.140.3;91. 140.60
© BIS 2003
BUREAU OF INDIAN STANDARDS
MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002
April 2003 Price Group 10
Plastic Piping System Sectional Committee, CED 50
FOREWORD
This Indian Standard (Part 3) (First Revision) was adopted by the Bureau of Indian Standards, after the draft
finalized by the Plastic Piping System Sectional Committee had been approved by the Civil Engineering Division
Council.
The preparation of a code of practice for plastics pipe work for potable water supplies was taken up to make
available comparative properties of different types of plastics pipe. Additionally, it would give guidance for
their selection for different situations arising in practical usage and also to recommend sound practices for the
installation, jointing and testing of such pipe systems. It was hoped that the code would assist in greater application
of plastic pipes. Part 3 of the standard covered laying and jointing of unplasticized polyvinyl chloride (UPVC)
pipes.
The other parts published so far in the series are:
Part 1 Choice of materials and general recommendations
Part 2 Laying and jointing polyethylene (PE) pipes
In the formulation of the original standard, due weightage was given to international co-ordination among the
standards and practices prevailing in different countries in addition to relating it to the practices in the field in
this country. This was met by deriving assistance irom BS : CP312 : Part 2 : 1973 'Code of practice for plastics
pipe work for the conveyance of fluids under pressure' issued by the British Standards Institution.
With the advent of globalization and the likelihood of the influx of foreign competition, the committee felt that
this standard should be brought even more in line with revised international standards. The need was also felt to
give a more comprehensive treatment to the entire area of handling, transportation, storage, installation and very
importantly, the testing of pipelines prior to their commissioning. For this purpose, assistance was drawn from
the European Standard prEN 1452-6 : 1994 'Plastics piping systems for water supply — Unplasticized poly
vinyl chloride (UPVC) Part 6 : Recommended practice for installation as well as other literature'. Further, the
sections on heat application method have been altogether deleted from this revision, as it is felt that this is an
operation requiring considerable skill by trained personnel and therefore is not recommended for use by normal
installation teams in the field.
The composition of the Committee responsible for formulation of this standard is given in Annex A.
IS 7634 (Part 3) : 2003
Indian Standard
PLASTICS PIPES SELECTION, HANDLING, STORAGE
AND INSTALLATION FOR POTABLE WATER
SUPPLIES — CODE OF PRACTICE
PART 3 LAYING AND JOINTING OF UPVC PIPES
(First Revision )
1 SCOPE
1.1 This code of practice (Part 3) gives guidance for
the proper methods of laying and jointing of
unpiasticized polyvinyl chloride (UPVC) pipe work
for potable water supplies (water mains and services
buried in ground and for the conveyance of water above
ground for both outside and inside buildings).
1 .2 This standard is applicable for cold water supplies
upto and including 45°C only. Appropriate de-rating
factors apply as per IS 4985 : 2000 'Unpiasticized PVC
pipes for potable water supplies — Specification {third
revision).
1.3 This standard does not purport to give guidelines
for designing and dimensioning of pipelines.
1.4 Local bye-laws shall be strictly observed whenever
used for municipal water distribution.
2 REFERENCES
The following standards contain provisions, which
through reference in this text, constitute provisions of
this standard. At the time of publication editions
indicated were valid. All standards are subject to revision
and parties to agreements based on this standard are
encouraged to investigate the possibility of applying the
most recent editions of the standards indicted below:
IS No. Title
4985 : 2000 Unpiasticized PVC pipes for potable
water supplies — Specification (third
revision)
5382: 1985 Specification for rubber sealing rings
for gas mains, water mains and
sewers
14182:1994 Solvent cement for use with
unpiasticized polyvinylchloride
plastics pipe and fittings
3 JOINTING TECHNIQUES
3.1 General
Unpiasticized PVC pipes are made by a continuous
extrusion process and are generally available as rigid
(hard), in-factory cut lengths. Pipes are supplied with
one of the following four end conditions:
a) Plain end, for jointing by means of separate
couplers, including mechanical joints,
b) Integral socket on one end, for solvent cement
jointing,
c) Integral socket on one end for jointing with
elastomeric sealing rings, and
d) Threaded, for jointing with threaded couplers.
3.1.1 Satisfactory jointing plays an important role in
successful performance of these pipes. Commonly used
joints are as follows:
a) Solvent welded joints,
b) Integral elastomeric sealing ring joints,
c) Mechanical compression joints,
d) Flanged joints,
e) Screwed or threaded joints, and
f) Union coupled joints.
3.2 Solvent Welded Joints
3.2.1 These are permanent in nature and can withstand
axial thrust (end-load bearing). This technique is used
with plain ended pipes with couplers, for pipes with
integral sockets as well as with injection moulded
fittings {see Fig. 1 ).
3.2.2 Pipes and fittings are manufactured to certain
tolerances to provide for small variations in the
extrusion, moulding and socket processes and are not
exact in size.
3.2.3 Solvent Cement
Consists essentially of a solution of vinyl chloride
polymer or copolymer dissolved in a suitable volatile
mixture of organic solvents. The solvent constituents
soften the mating surfaces, which diffuse into one
another to form a 'cold weld'.
3.2.3.1 Specification
Solvent cement shall conform to all the requirements
ofIS 14182.
IS 7634 (Part 3) : 2003
-PVC COUPLER
PVC PIPE
Fig. 1 PVC Solvent Welded Joint
3.2.3.2 Selection
Solvent cement is available in three grades of viscosity
as given below to cover a range of pipe sizes from
20 mm to 630 mm. Sufficient solvent cement shall be
applied so that a wet-film thickness adequate enough
to fill a gap in a pipe joint is formed. Selection is also
dependent on the climatic conditions prevalent at the
site.
Pipe Size
mm
Upto 50
63 to 160
Cement
Type
Regular bodied
Medium bodied
Minimum Minimum
Viscosity Wet
Film
A Thickness
MPa.s cp mm
90 90 0.15
500 500 0.3
Above 200 Heavy bodied 1 600 1 600 0.6
Medium bodied and heavy bodied cements may be
used for smaller pipe sizes than that shown in the table
above. The reverse does not hold good.
3.2.3.3 Storage
PVC solvent cement should be stored in a cool place
except when actually in use at the site. The cement has
a limited shelf life when not stored in hermetically
sealed containers. HDPE screw top containers are not
considered hermetically sealed. The cement is not
suitable for use if it exhibits an appreciable change
from the original viscosity, or if a sign of gelation is
apparent. Addition of thinners is not recommended for
restoring the original viscosity.
3.2.4 Procedure
3.2.4.1 Cutting
Pipes are supplied with square-cut and de-burred ends.
However, if pipes need to be cut to smaller lengths, use
a fine-toothed hand saw and a mitre box or a power saw
with wood-working blades, with a isuitable guide. The
cutting must not raise a burr or ridge on the cut end of
the pipe. Failure to remove the ridge will result in cement
in the fitting or socket being scraped away from the
jointing surfaces, leading to a dry joint with probability
of joint failure. Remove all burrs and ridges with a de-
burring knife, file, or abrasive paper {see Fig. 2).
3.2.4.2 Chamfering
Provide an approximately 2 mm wide, 1 5° chamfer on
pipe ends. A chamfer prevents the cement film from
being wiped off into the interior of the socket during
assembly.
3.2.4.3 Dry fit test
Before applying cement, insert the pipe end into the
socket of the next pipe or fitting to check that
interference occurs at about y 3 to % of the socket depth.
When the pipe and the socket are at their extreme
tolerances, the pipe can bottom (travel fully into) in
the socket. In such a case, it should be a snug fit. A
loose or wobbly fit will result in joint failure. Another
pipe end or the socket should be selected until these
conditions are fulfilled. Mark the insertion depth on
the pipe end with a felt tip pen or marker.
3.2.4.4 Cleaning
Surfaces to be joined must be free of dust, dirt, oil,
moisture and other foreign material. Wipe clean with
a dry cloth. If this is not sufficient, use a chemical (such
as dichloro-methane, methyl ethyl-ketone or
mechanical cleaner). With chemical cleaners, observe
safety precautions. Ketones are inflammable.
3.2.4.5 Application of cement
PVC solvent cement is quick drying, therefore it shall
be applied as quickly and carefully as possible and in
consistence with good workmanship. For larger sizes,
it is advisable for two workers to work simultaneously
on the pipe and socket. The surface temperature of the
IS 7634 (Part 3) : 2003
/
CUTTING
FILING
DEBURRING
Fig. 2 Pipe Cutting at Site
mating surfaces should be above 0°C but should not
exceed 45°C. Water can be used to cool the surfaces,
but these should be wiped thoroughly dry before
application of cement.
Dip the applicator brush in the solvent cement and
apply a liberal coat of cement to the end of the pipe
upto the insertion depth.
Apply a uniform thin coat of cement inside the socket,
working axially from the inside of the socket to the
outside. Do not apply any cement on the shoulders of
the socket (socket-to-pipe transition area). Care should
be taken not to apply excess cement inside the socket.
Excess cement m the socket will be pushed further into
the pipe during assembly and cause the pipe to soften
and weaken at that point. Hot and dry climates
generally require slightly thicker coatings of solvent
cement.
In climates with large differences between day and
night temperatures, it is advisable to make joints early
in the morning or in the evening when it is cooler.
Thus, the joints are prevented from being pulled apart
if the pipes contract.
3.2.4.6 Within 20 s after the last application of solvent
cement, insert the pipe into socket in a single steady
and every controlled but forceful action. Press it in
fully until it bottoms. No hammer blows should be
used. If there is any sign of drying of the cement coat
before insertion; the surface should be re-coated,
avoiding application of excess cement in the socket.
Once the insertion is complete, hold in place for 1 min
without shifting the pipe in the socket.
3.2.4.7 For large diameter pipes, two or more workers
may be needed for this operation. Mechanical equipment
such as levers and winches may be used. Care shall be
taken to ensure that force is not transmitted to previously
made joints. Until the cement is set, the pipe must be
prevented from backing out of the socket.
3.2.4.8 Immediately after assembly, wipe the excess
solvent cement from the pipe at the end of the socket.
A properly made joint will have a uniform bead around
its entire perimeter. Any gaps in this bead may be
indicative of an improper joint due to insufficient
cement or the use of a lighter-bodied cement than the
one recommended.
3.2.4.9 Setting times
Joints should not be handled until the requisite setting
time has elapsed. Recommended setting times are a
function of the ambient temperature at the job site as
given below:
Temperature
Recommended
setting times, Min
°C
h
15 to 40
1
5 -to 15
2
-5 to 5
4
-20 to -5
6
3.2.4.10 Installation and commissioning
After the setting time has elapsed, the pipe may be
handled carefully for installation. Pressure testing may
be carried out only after a curing period of 24 h.
3.3 Integral Elastomeric Sealing Ring Joints
Pipes are cut to length and bell socket in-line, to form
a groove for the elastomeric sealing ring, and supplied
in nominal lengths. Couplers and bends fabricated out
of UPVC pressure pipes are likewise socket.
3.3.1 Elastomeric sealing ring joint consists of an
elastomeric sealing element located in the groove in
the socket formed integrally with the pipe or fitting.
The sealing element (sealing ring) is automatically
compressed to form a pressure tight seal when the
spigot of the pipe is inserted into the socket.
3.3.2 These joints are non-end load bearing and it is
IS 7634 (Part 3) : 2003
essential to ensure the probability of joint separation
due to axial thrust. Joint separation can be prevented
in below ground applications by incorporating concrete
anchor blocks at appropriate places. In above ground
applications, anchor blocks must be provided (see 6.4).
Where large diameter pipes operating at high pressures
are involved, axial thrusts of several tonnes can be
developed.
3.3.3 In order to meet water quality and bio-
degradation requirements, elastomeric sealing rings are
usually made from synthetic materials like ethylene-
propylene-diene (EPDM) copolymer, styrene-
butadiene rubber (SBR) or a combination of synthetic
and natural rubber. The material should conform to
IS 5382.
3.3.4 Procedure
3.3.4.1 Pipes are supplied with the spigot end
chamfered. However, if pipes have to be shortened for
any reason, preparation of the ends will be necessary
before assembly.
3.3.4.2 Cutting of pipes, if required, must be done on
a jig to ensure that the cut is square to the axis of the
pipe. It is recommended that the pipe be marked around
the entire circumference prior to cutting. The pipe ends
must be chamfered at an angle of 15° with a medium
grade file and de-burred, (see Fig. 2).
3.3.4.3 Clean the spigot end of the pipe upto the insertion
depth (depth of the corresponding socket). Remove all
traces of mud, dirt, grease and gravel. Do not use any
chemicals or solvents for cleaning. For stubborn areas
of dirt, a very fine grade of emery or sand paper can be
used lightly. Wipe the pipe with a clean cloth moistened
with water and allow to dry completely.
3.3.4.4 Clean the inside of the socket. Remove all traces
of mud, dirt, grease and gravel. Do not use any
chemicals or solvents for cleaning. For stubborn areas
of dirt, a very fine grade of emery or sand paper can
be used lightly. Wipe the inside of the groove with a
damp cloth and allow to dry completely.
3.3.4.5 Mark the insertion depth on the spigot of the
pipe, if not already applied by the manufacturer. The
insertion depth is equal to the depth of the socket of
the pipe, measured upto the end of the parallel portion
of the socket (excluding the shoulder). This distance
is marked on the spigot (excluding the chamfer) with
an indelible felt-tip marking pen.
3.3.4.6 Insert the elastomeric sealing ring into the
groove. Rings to be used are system specific and shall
be those supplied by the manufacturer for his own
system. Form the ring into a heart shape by pinching a
portion of the ring from the inside (see Fig. 3). Insert
into the socket and release to seat into the groove.
Ensure proper seating of the ring in the groove. If the
ring is wrongly inserted it will lead to leakage. It may
also dislocate completely during assembly. Follow
instructions of the manufacturer.
3.3.4.7 Apply lubricant to the outside of the spigot
(consult the manufacturer). The lubricant should cover
the entire surface of the spigot for at least half the
insertion depth, starting from the end of the pipe. The
lubricant used should not have any detrimental effect
on the pipe, fittings or the elastomeric sealing ring and
shall not be toxic, shall not impart any taste or odour
to the water or encourage growth of bacteria. Do not
use oil-based or solvent-based lubricants.
3.3.4.8 Align the socket and spigot correctly in the
horizontal and vertical planes. Ensure that no sand or
dirt adheres to the lubricated surfaces of the pipe.
3.3.4.9 Insert the spigot end carefully into the socket.
Place a firm wooden block against the other end of the
pipe and, using a crow-bar as a lever, push home the
spigot upto the insertion depth mark (see Fig. 4). For
larger sizes of pipe, the use of a jointing jack may be
helpful. The jack can also be used to extricate a pipe
from a socket.
Fig. 3 Sealing Ring Joint Assembly
IS 7634 (Part 3) : 2003
3.4 Mechanical Compression Joints
These are commonly separate fittings made from UPVC
or metal and can be in the form of a coupler for connecting
pipes and fittings of the same material and of the same
dimensions, or as an adaptor for connecting
components of different materials and/or dimensions.
Generally compression fittings consist of four main
elements: body, elastomeric sealing rings, backing
(compression) rings and bolts. Both pipe ends should
be clean and free from damage before assembly is
begun. Each element is positioned on the pipe
separately, centred over the joint and the sealing rings
compressed between the body of the fitting and the
pipe by tightening the backing rings. Bolts should not
be over tightened and the manufacturer's
recommendations followed at all times (see Fig. 5).
3.5 Flanged Joints
These are used for jointing of UPVC pipes to other
pipes, fittings, valves and vessels made from dissimilar
materials, for example metals. The joint is made by
compressing a gasket or elastomeric sealing ring
between the mating surfaces of the flanges. Detailed
flange designs can vary considerably. Figure 6 and
Fig. 7 show two types of flanged joints.
3.6 Screwed or Threaded Joints
These are similar to the joints used with metal pipes.
If the pipe has to be joined by screw threads, only thick
walled pipe should be used and cut with taper threads.
Some manufacturers supply pipes with factory cut
EL ASTOMORIC (RUBBER) ^GROOVE
SEALING RING-
INSERTION-
DEPTH MARK
ON SPIGOT
V^
T
SOCKET
ASSEMBLED JOINT
PUSH
threads. Threaded pipes shall not be subjected to a
pressures exceeding two-thirds of the rating for
unthreaded pipes.
3.6.1 To obtain a good thread, it is essential to ensure
that:
a)
b)
c)
d)
e)
g)
Die holder is fitted with a guide of the correct
size. The guide must be properly screwed
down so that the two halves of the die are
flush with the face of the holder.
Die is not blunt.
Two halves of the die are adjusted so that they
are seated squarely in the holder and are
equidistant from the sides of the holder.
Observe the gaps on either side.
There are no sharp edges on the end of the
pipe. Provide a light chamfer with the edge
of a sharp knife.
Die holder is carefully slid over the pipe and
the two halves of the die adjusted with the
fingers so that the first threads seat lightly on
the pipe. Pipe must be properly centered. Now
tighten the adjusting screws % turn with a
spanner.
Thread is cut slowly and that after
every Vi turn, the die is turned back 14 turn.
Entire thread is cut in four equal passes.
Fig. 4 Bar and Block Assembly
Automatic threading machines may also be used.
Follow the instructions of the manufacturer.
3.6.2 Short pieces of thick-walled pipe may be threaded
at one end and solvent cemented onto normal walled
pipe at the other to make the connector pieces to
screwed metal fittings. This system may be used for
pipes upto 50 mm outside diameter.
3.6.3 No tape or paste shall be used for jointing. The
joint shall be made to firm hand tightness using only
strap wrenches.
3.6.4 There is no well defined increase in tightness at
assembly as there is with metal fittings. These joints
can therefore very easily be overstrained.
3.6.5 Injection moulded threaded joints are used for
jointing PVC to metal pipes. Injection moulded threads
are less notch sensitive than cut threads.
3.6.6 PVC to metal connections with threaded joints
should be made with the PVC as the male components
of the joint. PVC as the female component may be
used only when specific arrangements are made to
prevent over tightening or where both the threads are
of parallel form and the fluid seal is made by a separate
ring or gasket. A typical illustration of this is shown in
Fig. 8.
IS 7634 (Part 3) : 2003
Fig. 5 Mechanical Compression Joint
METALLIC BACK-UP
FLANGE
PVC VANSTONE
OR F IP
-I!
PVC PIPE SOLVENT
WELDED OR PVC
FLANGED TAIL PIECE
METAL PIPE WITH
FLANGES(SCREWED OR
WELD€D FLANGE)
NUT AND BOLT
Fig. 6 Flanged Joints with PVC
BOLT AND NUT
RUBBER GASKET
2ZZZZZZZZZZZZ3
PVC FLANGED
TAIL PIECE
CONVENTIONAL PIPE
(WELDED OR SCREWED
TO METALLIC FLANGE)
Fig. 7 Flange Joints (Jointing PVC Pipes and Other Conventional Pipes Using PVC Flanged Tail Piece)
6
IS 7634 (Part 3): 2003
3.6.7 While connecting metallic water taps to the PVC
pipes in domestic plumbing, it is recommended to use a
metallic coupler to the tap and then connect the same to
the PVC pipe using injection moulded threaded joints.
The metallic part alone is supported and not the PVC.
The unsupported length from the face of the wall should
not be more than 1 00 mm for satisfactory operation and
a strong coupling should be provided on the face of the
wall at the point of overhang. For any repairs on the
tap, the tap should be removed from the metal coupler
to avoid working on it in-situ. A typical illustration of
such a connection is shown in Fig. 9.
3.7 Union Joint
This is a form of flanged joint, but the faces are held
together by a screwed connection. A composite metal
and PVC socket union is a very satisfactory method of
jointing PVC to screwed metallic fittings. A typical
illustration of union is shown in Fig. 10.
3.8 Service Connections
3.8.1 Both metal and plastic saddles are available for
the off take of service connections from larger bore
pipes (50 mm diameter and above). One type of saddle
consists of a half round moulded unplasticized PVC
section which is solvent cemented to the pipe surface.
The outside of the PVC section has a boss on to which
the service connection may be screwed. Another type
consists of two half round sections of metal or PVC
which are bolted together or held around the pipe by
wedge grips. A seal is formed between the saddle and
the pipe by a rubber O-ring compressed between the
PVC PIPE SOLVENT
WELDED
•»'m»(w»^ —
METALLIC PIPE
SCREWED END)
1
'//////////////XT.
s^^^vvvv ^^
PVC THREADED
ADAPTOR (MALE)
METALLIC THREADED
COUPLER IFEMALE )
Fig. 8 Jointing PVC Pipe to Conventional Pipe Using Threaded Joints
PVC PIPE SOLVENT
WELDED
PVC THREADED
COUPLER
ETAL
COUPLER
METAL
tap-
Fig. 9 Connection of PVC Pipe to Metallic Water Taps
7
IS 7634 (Part 3) : 2003
a) UNION COUPLER
b) UNION ADAPTER
c) ADAPTER BUSH
-METALLIC
UNION
/
PVC PIPE SOLVENT
WELDED-
<AUW.uiu.xOTa
L ""^ A H
PVC THREADED
ADAPTOR
Fig. 10 Types of Union Joints
pipe and the under surface of the section. The service
connection is taken from a boss on the upper section.
3.8.2 Conventional equipment for tapping under
pressure may be used with these service connections
using a special trepanning cutter to pierce the pipe wall.
Some ferrules have self contained cutters for this
purpose. Ferrules should not be screwed directly into
un-reinforced pipes without the introduction of a
reinforcing saddle piece. A typical illustration of union
is shown in Fig. 1 1.
4 TRANSPORT, HANDLING AND STORAGE OF
PIPES
Because UPVC pipes are durable and light, they are
more likely to be mishandled. Care should be taken to
ensure that pipes are not damaged during handling,
storage and transport.
4.1 Transport
4.1.1 When transporting pipes, flat bed vehicles should
be used. The bed should be free from nails and other
projections. When practical, pipes should rest
uniformly on the vehicle over the whole length
(see Fig. 12).
4.1.2 The vehicles should have side supports
approximately 2 m apart and the pipes should be
secured effectively during transport. All posts should
be flat with no sharp edges.
4.1.3 When loading spigot and socket pipes, the pipes
should be stacked on the vehicle so that the sockets do
not take excessive loads.
4.1.4 Where pipes overhang the vehicle, the amount
of overhang should not exceed 1 m.
IS 7634 (Part 3) : 2003
METALLIC FERRULE
PVC THREADED SADDLE
MALE)
RING GASKET
PVC PIPE
PVC SERVICE
SADDLE
BOLT
(FOR
Fig. 1 1 Ferrule Connection Using Service Saddle
4.1.5 High stiffness pipes should be placed at the
bottom of the load and low stiffness pipes at the top.
4.1.6 Care should be taken to avoid positioning the
pipes near to any exhaust systems or any other potential
hazards such as diesel oil, paints or solvents.
4.1.7 Pipes should be inspected prior to off-loading.
4.1.8 When pipes are transported in bundles, the
bundles should be secured effectively and off-loaded
as described in 4.3.
4.2 Handling
4.2.1 UPVC pipes should be handled keeping in mind
that they are made of plastic and are also susceptible
to damage if mishandled. They should not be thrown,
dropped or dragged. Single pipe of upto 250 mm can
be lifted by two men without difficulty (see Fig. 13,
14 and 15).
4.2.2 Mechanical lifting equipment used for lifting
pipes and pipe bundles should not damage the pipe.
Fork-lift forks should be flat and protected. Cranes
should have spreader bars. No wire ropes, chains or
hooks should be used. Slings should be made of rope
or webbing 7 to 10 cm wide (see Fig. 16).
4.2.3 If pipes have been telescoped for transporting,
the inner pipes should be removed first and stacked
separately.
INCORRECT WAY TO LOAD PIPES
CORRECT WAY TO LOAD PIPES
Fig. 12 Transportation
9
IS 7634 (Part 3): 2003
4.2.4 Resistance to impact is reduced in cold weather.
Extra care needs to be taken at temperatures
around 0°C. At temperatures below -15°C, special
instructions from the manufacturer should be
obtained.
4.3 Storage
4.3.1 Pipes should be stacked on a surface flat and
free from sharp objects, stones or projections in order
to avoid deformation or damage. Ends of pipes should
be protected from abrasion and chipping.
4.3.2 The pipes should be supported evenly over their
whole length. The bottom layer of the stack should be supp-
orted on wooden battens of uniform size, at least 50 mm
wide and placed not more than 2 m apart. The sockets
should not bear on the ground {see Figs. 1 7 and 18).
4.3.3 Pipes of different diameters and different pressure
classes should preferably be stacked separately.
4.3.4 Factory packed pipes should packed in bundles
with timber battens at minimum three places. These
should not be unpacked until required for use.
F^tT 3z&
\y
CQCOYXJ
WRONG
RIGHT
Fig. 13 Handling
Fig. 14 Handling and Transportation
Fig. 15 Manual Handling
10
IS 7634 (Part 3) : 20D3
NON- METALLIC
WIDE BAND
WEBBING
WEBBING POSITION
OUTSIDE TIMBER
BATTENS
Fig. 16 Mechanical Lifting
4.3.5 Bundles in depots should be stacked no more
than three units or 2 m high, whichever is lower, as
shown in Fig. 19.
4.3.6 On the site, bundles should be stacked no more
than two units or 1 m, whichever is lower.
4.3.7 Timber framed bundles should be stacked timber
to timber.
4.3.8 It should be necessary to store pipes loose or if
they are received loose, care should be taken to see
that each layer of the stack lies alternatively with the
sockets on opposite ends of the stack. The sockets of
SOCKETED PIPES STORED
WITH SOCKETS AT
ALTERNATE ENDS
MAX. STACK HEIGHT
7 LAYERS OR 1-5 m
■MAXIMUM
WIDTHS Om
STOUT TIMBER
BEARERS
Max. 1-5 m
CENTRES
Fig. 17 Stacking in Depot
1m Max.
Fig. 18 Stacking at Site
11
IS 7634 (Part 3) : 2003
each pipe must project sufficiently for the pipes to be
supported correctly along the whole length (parallel
stacking) [see Fig. 20(A)].
4.3.9 The sides of the stack must be supported with
timber battens to prevent stack collapse. The side
supports should be spaced not more than 3 m apart.
The width of the bottom layer should not exceed 3 m.
4.3.10 Alternatively, pipes can also be stacked with
adjacent layers lying at right angles to each other (cross
stacking), while observing that the sockets lie as stated
in 4.3.8 [see Fig. 20 (B)].
4.3 .1 1 Stack height should not exceed 1 . 5 m in depots and
stores or 1 m at construction sites (see Fig. 17 and 18).
4.3.12 Prolonged exposure of the pipes to sunlight must
be avoided. Pipes must be protected from ultra-violet
light (sunlight), which would otherwise cause
discolouration and can reduce the impact strength of
the pipe. However, resistance to internal water pressure
is not reduced. Suitable protection by a free-venting
cover (canvas tarpaulin or polyethylene sheeting) is
ADDITIONAL
SUPPORT
BATTENS
07m
, 2-25m . 225m °'*V
> ,
_
fc=H
r— 1 J
2m Max.
J.
Fig. 19 Stacking of Bundled Pipes
20A Parallel Stacking
20B Cross Stacking
Fig. 20 Stacking of Pipes
12
IS 7634 (Part 3) : 2003
recommended if the total exposed time is likely to
exceed 4 weeks (see Fig. 2 I ).
4.3.13 Pipes should be stored away from any heat
source and should not be in contact with any other
potential hazards such as diesel oils, paints or solvents.
4.3.14 If PVC pipes are date coded at the time of
manufacture, it is recommended to rotate stocks on a
'first-in-first-out' basis.
5 STORAGE, HANDLING AND TRANS-
PORTATON OF FITTINGS, VALVES AND
ANC1LLARIES
5.1 Because UPVC fittings, valves and ancillaries are
light and easy to handle, they are more likely to be
mistreated than metallic components.
Throughout all stages of storage, handling and
transport they should be preserved from damage and
contamination and be kept separate from and not
temporarily jointed to the pipes until required for
installation. When fittings are provided in packaged
form, they should be retained in the individual package
provided by the supplier, together with all associated
rings, gaskets, nuts, bolts and accessories.
5.2 The impact resistance of UPVC fittings, valves and
ancillaries is reduced in cold weather and more care
needs to be taken when handling these products at
temperatures below 0°. If temperatures fall below -1 5°,
special instructions should be obtained from the
manufacturer.
5.3 Fittings, valves and auxiliaries should be used in
the order of delivery to ensure the correct rotation of
stock.
5.4 Sealing rings should be stored in a cool place with
temperatures not exceeding 35°, preferably below 25°.
The seals should be protected from light, in particular
strong sunlight and artificial light with a high ultra-
violet content. They should not be stored in a room
with any equipment capable of generating ozone, for
example mercury vapour lamps, high voltage electrical
equipment which may give rise to electrical sparks of
silent electrical discharge. The seals should be stored
in a relaxed condition free from tension, compression
or other deformation. For instance, they should not be
suspended from any part of the circumference. The
seals should be maintained in a clean condition; they
should not be removed from their containers until
shortly before use. Shelf-life of sealings rings depends
on the material of manufacture. Consult the
manufacturer.
While handling, care should be taken that they are not
abraded, scratched or nicked and that the sealing lips
are not damaged in any way.
6 UNDERGROUND INSTALLATION
6.1 General
The long term performance of UPVC pressure pipelines
is directly affected by the quality of workmanship and
materials used in installing the product. Competent
supervision of all stages is important.
In buried pipelines, the pipe and the soil form an
integral structure. When installed properly, UPVC pipe
gains strength due to the support of the soil. The soil
and pipe wall deflect or compress depending on any
one combination of the following three factors:
a) Pipe stiffness,
b) Soil stiffness, and
c) Load on the pipe.
6.2 Trenching
6.2.1 Location
Drinking water pipelines should not be located below
sewerage pipelines.
Fig. 2 1 Protection from Sunlight
13
IS 7634 (Part 3) : 2003
Where a pipeline runs parallel to other pipelines or
cables, the distance between them should not be less
than 0.4 m.
At points of congestion, a distance of 0.2 m should be
maintained unless steps are taken to prevent direct
contact.
6.2.2 Width
Trenches should be of adequate width to allow the burial
of pipe, while being as narrow as practical. If expansion
and contraction are not problems and snaking of pipe is
not required, minimum trench widths may be obtained
by joining the pipe outside the trench and then lowering
the piping into the trench after the testing. A trench width
of two or three times the pipe diameter is a good rule of
thumb. See Tables 1 and 2 for narrow (unsupported)
and supported trench widths. Where necessary to prevent
cave-ins, trench excavations in unstable soil shall be
adequately supported. As backfill is placed and sheeting
withdrawn, the void left by the withdrawn sheeting shall
be filled and compacted before withdrawing the next
increment.
Table 1 Unsupported Narrow Trench Width,
Minimum
(Clause 6.2.2)
Table 2 Supported Trench Width, Minimum
(Clause 6.2.2)
SI No.
Nominal Pipe
Sizes
Trench Width
(Diameter in mm) Number of Pipe Width
Diameters
(Approximately) mm
63 7.1 450
ii) 75 6.0 450
iii) 90 5.0 450
iv) 110 4.0 450
v) 125 4.0 500
vi) 140 3.9 550
vii) 160 3.5 560
viii) 180 3.2 580
ix) 200 3.0 600
x) 225 2.8 630
xi) 280 2.4 680
xii) 315 2.25 710
xiii) 355 2.1 760
xiv) 400 1.9 760
6.2.3 Trench Bottom
The trench bottom shall be constructed to provide a
firm, stable and uniform support for the full length of
the pipeline. There should be no sharp objects that may
cause point loading. Any large rocks, hard pan, or
stones larger than 20 mm should be removed to permit
a minimum bedding thickness of 100-150 mm under
the pipe. For pipes of diameters 100 mm or greater,
bell holes in the bedding, under each socket joint, shall
be provided by removing some of the bedding material,
to accommodate the larger diameter of the joint and to
permit the joint to be made properly.
SI No.
Nominal Pipe
Sizes
(Diameter in mm)
Trench Width
Number of Pipe
Width
Diameters
(Approximately)
mm
i)
63
14.2
900
ii)
75
12.0
900
iii)
90
10.0
900
iv)
110
8.2
900
v)
125
7.2
900
vi)
140
6.4
900
vii)
160
5.6
900
viii)
180
5.0
900
ix)
200
4.5
900
x)
225
4.2
940
xi)
280
3.5
990
xii)
315
3.1
1 040
xiii)
355
3.1
1 090
xiv)
400
2.85
1 140
6.2.4 Excavated Material
Excavated material should be deposited at a sufficient
distance away from the trench to prevent damage to
the pipeline through falling stones or debris.
6.2.5 Soil
The type of soil and the amount of compaction of the
pipe embedment directly affect the performance of
the pipeline. With proper embedment soil and
compaction, greater burial depths are possible and
higher external pressure capability and less pipe
deflection will occur.
6.2.6 Minimum Cover
The following guidelines should be followed:
a) If frost is anticipated, locate the pipeline
below the frost line.
b) A minimum cover of 0.9 m when truck traffic
is expected.
c) A minimum cover of 1 .8 m when heavy truck
or locomotive traffic (dynamic loads) is
expected. Usually pipe below 2.0 m of cover
are not affected significantly by dynamic
loads. If the application prevents deep burial
of the pipe and heavy traffic passing over the
pipe is expected, it would be advisable to use
steel or reinforced concrete casing to prevent
damage to the pipe.
d) For high static and/or surcharge loads, it is
important to use pipes of an appropriate
stiffness in order to ensure the initial
deformation of the pipe is maintained within
a limit of 5 percent, maximum
14
IS 7634 (Part 3) : 2003
6.2.7 Bedding and backfill material may be available
by selection from 'as dug' excavated material. Such
soils as free draining coarse sand, gravel and soils of a
friable nature, that is soils which crumble easily, are
considered suitable.
'As dug' material must be free from boulders, sharp
stones, flints, lumps of clay or chalk. Contaminated
soil and any organic material should be discarded.
Where excavated material is not suitable, suitable
imported material must be used.
Prepare the bedding by laying on soft soil and
alternatively compacting and watering sparingly
until an effective thickness of 100 to 150 mm is
achieved.
6.2.8 At the end of each working period, the pipeline
should be temporarily capped to prevent the ingress
of surface water, sand, dirt, debris and vermin.
6.3 Laying
Lay the pipes in the trench after ensuring that bell
holes have been provided for at the appropriate places
in the bedding (pipes of diameter 110 mm or less,
with no live load application, do not require bell holes
in the trench bottom). These have to be refilled
carefully after testing of the pipeline and prior to
complete backfilling of the trench. Though not
essential, the pipes should be laid with the spigots
entered into the sockets in the same direction as the
intended flow of water.
6.4 Anchoring
6.4.1 To sustain thrust caused by internal pressure,
concrete anchor blocks should be provided at all
changes of direction, tees, blank ends, large
reductions in diameter and valves. The purpose of
the anchor block is to transfer the total thrust to the
trench sides. It is therefore important to take account
of the load-bearing capacity of the surrounding
ground {see Fig. 22).
6.4.2 Recommended mixture for concrete is one part
cement, two parts washed sand and two parts gravel.
6.4.3 Where concrete would be in direct contact with
the pipe or fittings, these should be wrapped with a
compressible material, for example rubber sheet or
foamed polyethylene sheet, to accommodate creep and
prevent the occurrence of high local stress
concentrations. The compressible material should not
contain substances which could attack the pipe, for
example plasticizers.
6.4.4 Typical thrusts generated are given in Table 3.
Thrust forces on reducers need only be considered
where the reduction in diameter is large (315 to
90 mm). In such cases, the thrust is the product of test
pressure and annulus area:
F = 2p. 7T.
Df-D
where
F = thrust force;
p = test pressure;
D. = inside diameter of the larger pipe; and
D e = outer diameter of the smaller pipe.
6.5 Backfilling
6.5.1 The first sidefill or haunching layer should be
placed by hand and compacted in layers under the lower
quadrants of the pipe upto the spring level (half the
vertical diameter) of the pipe. Compaction can be done
by careful trampling with the feet or with tamping tools.
6.5.2 Care should be taken to leave adequate area
around the joint free of backfill to allow for inspection
during testing of the pipeline.
6.5.3 Successive layers of backfill of 75 mm thickness
may then be placed over and compacted to a height
above the crown of not less than 150 mm. Light
vibrating machinery may be used, but not directly
above the pipe.
6.5.4 If imported granular, free-flowing material is
used, this should be able to flow around the pipe and
can easily be raked into position to form a complete,
self-compacting surround. With carefully controlled
pouring, the whole surround upto 150 mm above the
crown may be placed in one pass.
6.5.5 Where side sheeting trench support has been used,
this should be partially withdrawn during the placing
of the side fill and surround, so that no voids are left
between the pipe and the trench walls.
6.5.6 On completion of the surround to the pipe,
suitable excavated material may be then replaced as
backfill in 250 mm compacted layers upto the top of
the trench. No heavy compaction equipment may be
employed until there is at least 300 mm of fill above
the crown of the pipe.
6.5.7 Metal marker tape can be laid into the final backfill
to enable electronic location of the pipeline, if required.
7 ABOVE GROUND INSTALLATION
7.1 Since solvent cemented joints will sustain axial
thrust caused by internal pressure (see 3.2), it is
strongly recommended that UPVC pipes and fittings
systems installed above ground or in service ducts
constructed below ground are jointed by the solvent
cement method. In certain circumstances the
manufacturer's advice should be considered. Other
15
IS 7634 (Part 3) : 2003
>;o'.'.-'o ■■•.*.•' ':
CONCRETE
"
W J> + J r.- 5 .- ! .;i; J 4
*»
&$
^u*
:&■???£-?
m
PROTECTIVE
COVERING
REDUCER (Section) GROUND L EVEL
RISER (SECTION)
Fig. 22 Various Types of Poured Concrete Anchoring
16
IS 7634 (Part 3) : 2003
Table 3 Thrust Forces for Blank Ends and Bends
(Clause 6.4.4)
SI No. Nominal
Thrust on
Radial Thrust on
Bends kN/bar
Diameter
Blank End
of Various
Angles
d„ mm
(kN/bar)
(kN/bar)"
90°
45°
22.5°
11.25°
(1) (2)
(3)
(4)
(5)
(6)
(7)
i) 63
0.31
0.44
0.24
0.12
0.06
ii) 75
0.44
0.62
0.3
0.17
0.09
lii) 90
0.64
0.90
0.49
0.25
0.12
iv) 110
0.95
1.34
0.73
0.37
0.19
v) 125
1.23
1.74
0.94
0.48
0.24
vi) 140
1.54
2.18
1.18
0.68
0.30
vii) 160
2.01
2.84
1.54
0.78
0.39
viii) 180
2.54
3.60
1.95
0.99
0.50
ix) 200
3.14
4.44
2.40
1.23
0.62
x) 225
3.98
5.62
3.04
1.55
0.78
xi) 250
4.91
6.94
3.76
1.92
0.96
xii) 280
6.16
8.71
4.71
2.40
1.12
xiii) 315
7.79
11.02
5.96
3.04
1.53
xiv) 355
9.90
14.00
7.58
3.86
1.94
xv) 400
12.57
17.77
9.62
4.90
2.46
xvi) 450
15.90
22.49
12.71
6.21
3.12
xvii) 500
19.63
27.77
15.03
7.66
3.85
xviii) 560
24.63
34.83
18.85
9.61
4.83
xix) 630
31.17
44.08
23.86
12.16
6.11
" The values in the table are
per bar of internal pressure.
;//\"\//s\\\//s^
BEDDING
EXCAVATED
TRENCH WIDTH
^A\\^\\V^
*'•.. r
..' fr
, ' t> ,..>
, PIPE
_! EMBEDMENT
FOUNDATION
(OPTIONAL)
Fig. 23 Terminology of Trench Cross- Sections
17
IS 7634 (Part 3) : 2003
forms of end-load bearing joints are also acceptable
for inclusion in above ground installations.
7.2 UPVC pipes may fracture if fluids contained within
the pipes are allowed to freeze. Sections which are
likely to freeze should be isolated and drained, or
insulation provided to prevent damage.
7.3 The coefficient of linear expansion of UPVC is
approximately 60 * 10 6 m/m/°C or 0.06 mm/m/°C.
The following equation is used for calculating the
dimensional variation:
AL = 0.06 Lx AT
where
AL = variation in length, in mm,
L - initial length, in m, and
AT = change in temperature of the pipe wall, in °C.
Example : For a temperature variation of 20°C, a
UPVC pipe 10 m long will have a variation
in length of 0.06 x 10 x 20 = 12 mm
Where ambient temperatures are reasonably constant,
the change in pipe wall temperature can be taken as
being equal to the change in fluid temperature. Where
this is not the case, the pipe manufacturer's advice
should be obtained.
For length variations with temperature, see Fig. 24 and
Fig. 25.
7.4 Pipes should be installed in such a way as to ensure
that the minimum amount of stress is induced in the
system from movement caused by expansion/
contraction or any other forces.
Examples of correct and incorrect installation are
shown in Fig. 26.
7.5 UPVC pipes should not be restrained in the hoop
direction by straps or clamps made from unyielding
material. The use of a compressible material such as
rubber of foamed polyethylene between clamp and pipe
is recommended.
Pipes should be free to move in the longitudinal
direction unless otherwise fixed for expansion/
contraction control.
Recommended distances for horizontal or vertical
support centres are given in Table 4.
7.6 UPVC pipes should be installed at sufficient
distances from sources of heat to prevent damage due
to radiant heat.
7.7 All control devices (such as valves) should be
correctly supported so that the pipe is not subjected to
any operational torsion strain. In addition, the support
provided should be sufficiently robust to prevent
bending and direct stresses being induced by the weight
of the device.
7.8 UPVC pipes and fittings installed above ground
should be protected from direct sunlight.
8 INSTALLATION IN DUCTS
Where possible, pipes with end-load bearing joints
should be used for installation inside inaccessible ducts.
In addition, rings should be fitted to the pipe to provide
optimum support and to facilitate the withdrawal of
the pipe in the event of rupture {see Fig. 27 for typical
detail). For large diameter pipes, or where the duct is
large compared to the pipe but not large enough to be
accessible, other methods of securing the pipe may be
necessary (see Fig. 28). The opening between the pipes
and the ducting system should be sealed at the ends.
Table 4 Minimum Supports for Unplasticised PVC Pipes
{Clause 7.5)
All dimentions in millimetres.
SI No.
Outside
Distance Between
Supporting Centres for
Vertical Pipes
Diameter of
Pipe
Water at Temperatures Horizontal Pipes
20 °C to 45 "C
-"
-
d<
20 "C
25 °C
30 °C
35 °C
40 °C
45 °C
(I)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
>)
16
750
670
600
500
400
—
800
ii)
20
850
770
700
600
500
—
900
iii)
25
900
820
750
650
550
500
1 000
IV)
32
1 000
920
850
750
650
570
1 200
v)
40
1 100
1 050
1 000
900
800
700
1400
vi)
50
1250
1 200
1 150
1050
950
800
1 600
vil)
63
1 400
1 350
1 300
1 200
1 100
970
1 800
viii)
75
1 500
1 450
1400
1 300
1 200
1070
2 000
IX)
90
1 650
1 600
1550
1450
1 350
1 200
2 200
XI
110
1 850
1 800
1 750
1 650
1 550
1 370
2 400
xi)
140
2 150
2 100
2 050
1950
1 850
1 720
2 500
xii)
160
2 250
2 200
2 150
2 070
2 000
1 850
2 500
xiii)
225
2 500
2 450
2 400
2 320
2 250
2 120
2 500
xiv)
250
2 575
2 500
2 450
2 400
2 300
2 200
2 500
IS 7634 (Part 3) : 2003
o
LjJ
o
z
LiJ
ct
UJ
u.
U-
Ui
a.
z>
<
cc
LU
0.
2
UJ
10 15 20 25 30 35 40
VARIATION IN LENGTH , AL (mm)
45 60
55
60
Fig. 24 Thermal Expansion/Contraction of PVC Pipe
200 250 300 35T) 400 500 600
FLEXIBLE -ARM, a (mm)
800
1000 1250 1500 1750 2000
Fig. 25 Minimum Free Lengths, a, of Flexible Arm
19
IS 7634 (Part 3) : 2003
COMPRESSIBLE
MEMBRANE
COMPRESSIBLE
MEMBRANE
FINGER TIGHT + )4 TURNS
IF MOVEMENT IS HTO BE
ACCOMODATED UNDER THE
MEMBRANE LEAVE A SMALL
GAP BETWEEN PIPE * SADDLE
THREADED NUT
OVER TIGHTENED
NO MEMBRANE
£
W
X
PIPE BEARING ON
ROOF TRUSS
Fig. 26 Correct and Incorrect Installation
8.1 Installation of pipes in accessible ducts should be
as described for above ground installation under 7.
9 TESTING
WARNING : Pressure tests should never be carried
out using compressed air or gasses.
9.1 Preparation
9.1.1 Pipe systems should be hydraulically tested in
lengths appropriate to the diameters and site conditions.
Pipelines longer than 800 m may require testing in
sections. Preferably, the length selected for test is
between 300 m and 500 m.
9.1 .2 Preferably, the testishould be carried out between
blank flanges (see Fig. 29). Testing against closed
valves is not recommended, unless there is no
alternative.
9. 1 .3 Do not support the end pieces of the test section
against the already laid pipes of the proceeding
section.
9.1.4 Testing should not take place until any concrete
used for anchoring has fully cured (normally 72 h) and
attained its required strength. Solvent cemented joints
must be allowed to harden for a minimum of 24 h
before being subjected to test conditions.
9.1.5 It is important to provide sufficient backfill over
the main barrel of the pipe, to prevent displacement
and to maintain stable temperature conditions. Leave
joints free for inspection.
9.1.6 The test position should be located at the lowest
point of the pipeline profile to encourage expulsion of
air as the pipe is being filled with water. Adequate air
release mechanisms should be located at all high points
along the line.
9.1.7 Test-ends should be designed to enable the
measured filling and subsequent emptying of the
pipeline. Air bleed should also be incorporated at each
end.
9.1.8 Pressurizing equipment should be adequately
sized. Check all seals and non-return valves prior to
the test. Pressure gauges should have an accuracy of
± 0.2 bar. Automatic pressure recording equipment is
recommended.
9.1.9 Before filling the pipeline, all line valves and air
venting systems should be checked open. All air must
be removed from the system.
9.1.10 Fill the system slowly. Water velocity must not
exceed 0.6 m/s. Potable water pipelines should be tested
with potable water only. After charging, close all air
valves and check proper action of automatic valves.
20
IS 7634 (Part 3) : 2003
TIMBER BRACING
AND SUPPORT
{SHORT DUCTS)
PROTECTIVE
SLEEVE
Fig. 27 Typical Details of Pipes Installed in Small Ducts
METAL STRAP
SLEEVE
MASS CONCRETE
Fig. 28 Typical Details of Pipes Intalled in Large Ducts
21
IS 7634 (Part 3): 2003
PRESSUR1ZATION BY HAND
OR
RECIPROCATING PUMP
LOW
>///////,
VALVE FOR AIRBLEED
SAMPLING POINT AND/OR
BURST PRESSURE
RELEASE
LARGE BUDERBURG
PRESSURE GAUGE
ABOVE GL
FLANGES ADAPTED TO
SIZE AND END OF PIPE
LINE UNDER TEST
FLANGES ADAPTED TO
SIZE ANOEND OF PIPE
LINE UNDER TEST
□D
H^
TEST PIPE USING
FLANGED TEE WITH
LATERAL SUPPORT
SECTION OF PIPEINE
UNDER TEST
SPECIAL AND PIECE
USING FLANGED AND
TAPERED DUCKFOOT BEND
HIGH
7^7P7
29A Typical Layout Details for Test Ends
©
WATER INLET FROM
PRESSURE PUMP FLOW
f ^JOMA SWAB
BLANK FLANGE OR TEST PIPE TAPPED
TO SUIT PUMP CONNECTION
TEMPORARY
THRUST
BLOCK
, BLOUK —7
©
VJItl
FOAM SWAB
EMERGING FROM J 1
--^3 L_ CAST IRON
DUCKFOOT
BEND
BOND'
FLANGE ADAPTORS
^=o
LOW POINT
BLANK FLANGE
BOLTED IN PLACE
&r
AIR RELEASE
COCK
iOL3^
HIGH POINT
29B Filling Behind a Form Swab
Fig. 29 Pressure Testing of Installed Pipeline
22
IS 7634 (Part 3) : 2003
9.1.11 During filling, a number of movements will be
seen in the pipeline. Allow the pipeline to stabilize
under a nominal pressure for a minimum of 2 h.
9.2 Test Pressures 1 '
9.2.1 The test should conform to the following
conditions;
a) be carried out at ambient temperature;
b) be applied for at least 1 h, but not more than
24 h; and
c) not exceed 1.5 times the maximum rated
pressure of the lowest rated component.
9.3 Applying the Test
9.3. 1 Allow the system to stabilize for 2 h after filling.
Apply pressure steadily. Observe pressure gauges
throughout and record the rates of pressure increase
recorded.
9.3.2 The pressure should be increased till the specified
pressure is reached at the lowest part of the section.
Maintain test pressure at this level, by additional
pumping if necessary, for a period of 1 h.
9.3.3 Close all valves and disconnect the pressurizing
unit. No further water should be allowed to enter the
system for a further period of 1 h.
9.3.4 During the test period, carry out a visual
examination of all joints and exposed connections.
9.4 Interpretation of the Results
9.4.1 There should be no leakage in any part of the
section.
9.4.2 If there has been a decrease in pressure during
this period other than due to leakage, the original
pressure is re-established by injecting a measured
quantity of water into the section.
9.4.3 The test is considered to be satisfactory if:
a) there is no decrease in pressure (a slight rise
in pressure is also, possible due to changes in
ambient temperatures),
b) the measured quantity of water required to
reinstate the pressure to the original test
pressure is less than the 'permissible
maximum' Q,
where
Q
4.5 litres per 1.6 km per 25 mm of
nominal bore per 30 m head of test
pressure per 24 h.
1 ' The recommended selection of test pressure is either: the nominal
pressure PN of the piping system (lowest PN of any component),
or 1 .5 times the actual operating pressure, whichever is greater.
The volume of water added is an allowance made to
compensate for the natural expansion/movement of the
pipe and flexible joints under pressure and for the
inevitable entrapment of small amounts of air within
the test length. In bubble form, this air compresses and
may pass in and out of solution at test pressures.
9.4.4 On completion of any test, the residual pressure
should be released slowly and in a carefully controlled
manner.
WARNING : The rapid decompression of any entrained
air may cause surge conditions which are potentially
dangerous both to the pipeline and to personnel.
9.4.5 All defects revealed in the test should be rectified
and the procedure repeated until a satisfactory result
is obtained.
10 CORROSION PROTECTION
10.1 UPVC pipes are resistant to all normal soil
conditions and require no corrosion protection.
10.2 UPVC pipe has a high resistance to chemicals
and withstands attack by concentrated mineral acids
(except nitric acid above 50 percent concentration),
alkalis, oils aromatic free petrol and alcohols.
However, UPVC pipes are sensitive to aromatic, or
chlorinated hydrocarbons, nitro compounds, esters,
ketones and strong oxidizing agents such as dry
chlorine gas.
10.3 Where adjacent metallic parts are protected, no
hot-or cold-applied coatings, or varnishes which contain
solvents, should come in contact with UPVC.
10.4 Soil above and around the trench containing
the pipeline should be protected from pollution
through spilled aromatic hydrocarbons, paint,
solvents, etc.
10.5 Anti-corrosion tape or similar protective materials
applied to metal connecting pieces should be of a type
which does not damage the UPVC pipes or fittings if
they come into contact with the pipeline.
11 PRESSURE SURGE (WATER HAMMER)
In operating conditions where surge pressures will
occur, suitable precautions should be taken. In such
circumstances, a surge analysis should be undertaken
to establish the magnitude and frequency of surge
pressure transients.
Pressures greatly in excess of normal sustained
operating pressures can be generated when fluid
velocities change rapidly. The magnitude of pressure
surge largely depends on the rate ofchange of velocity
and the modulus of the pipe material.
23
IS 7634 (Part 3) : 2003
Common causes of pressure surges are:
a) opening and closing of valves,
b) starting and stopping of pumps,
c) changes in turbine speeds,
d) changes in reservoir elevation,
e) liquid column separation, and
f) entrapped air.
12 REPAIRING DAMAGED PIPE
For the replacement of damaged underground PVC
pipe with a new pipe length, PVC double-socket
couplings are available from the manufacturer. The
replacement can be done with a length of pipe with
a spigot at each end and two double-socket repair
couplings, also called slip-couplings (see Fig. 30),
or a length of socket pipe plus one double-socket
repair coupling. In exposing the damaged area,
enough of the line should be excavated so that the
pipe can be flexed both to aid in handling the
damaged area and to insert the replacement
material.
12.1 Installing a Replacement Section with a
Double-Socket Repair Coupling (Slip-Coupling) on
Each End
1 2.1 .1 Cut out the damaged area. Ensure that cuts are
square to the axis of the pipe. This area should include
all the damaged area as well as include enough gap on
each side so that the replacement length with double-
socket couplings on each end can be accommodated
(see Fig. 30 and Fig. 3 1 ).
12.1.2 Chamfer the ends of the pipeline and put
reference marks on the ends.
12.1.3 Determine the necessary length of the
replacement pipe by measuring the gap dimension,
multiplying it by 2, and subtracting the result from the
length of the cut ou f section, as shown in Fig. 3 1(A).
Cut the replacement pipe to the proper length and
chamfer the ends.
12.1.4 Mount both the couplings on the ends so that
they are in a position as shown in Fig. 3 1 (B).
12.1.5 Insert the replacement assembly in the line and
slide the couplings into the proper position so that each
coupling is centred over the gap [see Fig. 3 1(C)].
12.2 Installing a Replacement Section with a Length
of Socket Pipe and One Coupling
12.2.1 Carry out the necessary cutting and chamfering
of the damaged area as per 12.1.2.
12.2.2 Mount the coupling on the cut and chamfered
end of the replacement length.
12.2.3 Complete the integral socket joint first by
pushing the socket end onto the cut spigot end.
12.2.4 Slide the double-socket coupling onto the cut
end of the line and centre it over the gap.
f
PVC REPAIR
COUPLER
RUBBER
RING
PVC PIPE
CHAMFERED ENDS
Fig. 30 PVC Double-Socket Repair or Slip-Coupler (Schematic)
24
IS 7634 (Part 3) : 2003
SITE CHAMFER
31A Faulty Joint Cut Out and Pipe Ends Chamfered
J=Ct
-=&
=0=L.
Jjzr
31 B Slip-Couplers Positioned with Make up Pipes in Position
rO
h if
■=D=
v U
:£}= r=Ct
^3 E=CP
■ O-t
^rj=x
31 C Slip-Couplers Moved into Position and Make up Piece
Fig. 31 Repairs Using Double-Socket Repair Couplers
25
IS 7634 (Part 3) : 2003
ANNEX A
{Foreword)
COMMITTEE COMPOSITION
Plastic Piping System Sectional Committee, CED 50
Organization
Engineer-in-Chiefs Branch, Army Headquarter, New Delhi
Ahmedabad Municipal Corporation, Ahmedabad
Brihanmumbai Mahanagar Palika, Mumbai
Building Materials and Technology Promotion Council, New Delhi
Calcutta Municipal Corporation, Kolkata
Carbon Everflow Limited, Nashik
Central Building Research Institute, Roorkee
Central Institute of Plastic Engineering Technology, Bhopal/Lucknow
Central Public Health Environment Engineering Organization,
New Delhi
Central Public Works Department, New Delhi
Chennai Metropolitan Water Supply and Sewerage Board, Chennai
Delhi Development Authority, New Delhi
Delhi Jal Board, New Delhi
Department of Telecommunications, New Delhi
Directorate General of Supplies and Disposals, Mumbai/Patna
Engineer-In-Chief s Branch, Army Headquarter, New Delhi
EPC Industries Pvt Limited, Nashik
Finolex Industries Limited, Pune
Housing and Urban Development Corporation Limited, New Delhi
Institute of Co-operative Management, Ahmedabad
Jain Irrigation Systems Limited, Jalgaon
Kerala Water Authority, Thiruvananthapuram
KWH Pipe India Limited, Raigad
Mahanagar Telephone Nigam Limited, New Delhi
National Environmental Engineering Research Institute, Nagpur
Representative(s)
Shri K. Prabhakar Rao (Chairman)
Shri N. P. Patel
Shri V. B. Parmar (Alternate)
Hydraulic Engineer
Deputy Hydraulic Engineer (Alternate)
Shri J. Sen Gupta
Shri D. K, Sanyal
Shri A. K. Biswas (Alternate)
Ms Seema Vaidya
Shri B. M. Valaskar (Alternate)
Shri L. K. Aggarwal
Shri Suresh Kumar Sharma (Alternate)
Dr Vijay Kumar
Dr Sania Akhtar (Alternate)
Adviser (PHE)
Assistant Adviser (PHE) (Alternate)
Chief Engineer (Design)
Superintending Engineer (S&S) (Alternate)
Shri R. N. Suriya Narayan Singh
Thiru V. Sivakumaran (Alternate)
Director (Materials Management)
Superintending Engineer (Design) (Alternate)
Shri S. K. Chhabra
Shri L. N. Kapoor (Alternate)
Shri Surinder Nath
Shri A. K. Nagar (Alternate)
Shrj A. K. Jain
Shri A. K. M. Kashyap (Alternate)
Shri R. A. Dubey
Shri Ajay Shankar (Alternate)
Shri K. L. Khanna
Shri Vinayak V. Shemblkar (Alternate)
Dr Dhananjay Rau
Shri K. Subramanian
Shri P. R. Srivastava (Alternate)
Dr S. M. Patel
Dr M. K. Pandey (Alternate)
Dr H. C. Mruthyunjaya
Shri S. Narayanaswamy (Alternate)
Deputy Chief Engineering (Material Management Unit)
Shri S. Sundram
Shri P. V. Kulkarni (Alternate)
Shri S. B. Lal
Shri A. K. Nagar (Alternate)
Dr M. V. Nanoti
Dr S. P. Pande (Alternate)
(Continued on page 27)
26
IS 7634 (Part 3) : 2003
(Continued from page 26)
Organization
NOCIL Limited, Thane
Public Health Engineering, Bhubaneswar
Public Health Engineering, Rooikee
Public Health Engineering Department, Jaipur
Public Health Engineering Department, Bangalore
Reliance Industries Limited, Mumbai
RITES, New Delhi
Supreme Industries Limited, Jalgaon
Tamil Nadu Water Supply and Drainage Board, Chennai
U. P. Jal Nigam, Lucknow
Uniplas India Limited, New Delhi
Vinplex India Pvt Limited, Chennai
In personal capacity (C- d 78B, Sushant Lok Phase 1, Gurgaon)
In personal capacity (196 Gulmohar Park, New Delhi 110 049)
BIS Directorate General
Representative(s)
Shri R. K. Bhatja
Shri A. R. Parasuraman (Alternate)
Shri P. C. Mahapatra
Shri G. C. Patra (Alternate)
Shri Sudesh Kumar Sharma
Superintending Engineer
Executive Enginheer (Alternate)
Shri Gulam Ahmed
Shri Subhash Sanzgiri
Shri V. B. Ramarao (Alternate)
Shri C. K. Sharma
Shri G. K. Saxena
Shri William Handones (Alternate)
Joint Chief Engineer (Contract)
Engineering Director (Alternate)
Materials Manager
Chief Engineer (PPR&D) (Alternate)
Managing Director
Shri G. K. Srinivasan
Shri P. Sai Venkata Prasad (Alternate)
Shri O. P. Ratra
Shri Kanwar A. Singh
Shri S. K. Jain, Director and Head (CED)
[Representing Director General (Ex-officio)]
Member Secreteraries
Shri J. K. Prasad
Director (CED), BIS
and
Shri R. K. Gupta
Joint Director (CED), BIS
PVC and ABS Piping System Subcommittee, CED 50 : 3
Vinplex India Pvt Limited, Chennai
All India PVC Pipe Manufacturers Association, New Delhi
Ashirvad Enterprises, Patna
Brihanmumbai Mahanagar Palika, Mumbai
Central Institute of Plastic Engineering and Technology, Bhopal
Central Public Works Department, New Delhi
Delhi Jal Board, New Delhi
Delhi Test House, New Delhi
Department of Telecommunications, New Delhi
Shri G. K. Srinivasan (Convener)
Shri P. Saivankata Prasad (Alternate)
Shri S. S. Gupta
Shri Deepak Poddar
Shri L. N. Poddar (Alternate)
Hydraulic Engineer
Deputy Hydraulic Engineer (Alternate)
Dr Vijaikumar
Dr Sania Akhtar (Alternate)
Chief Engineer (CSQ)
Executive Engineer (S&S) (Alternate)
Engineer-in-Chief (W)
Shri S. K. Chadha (Alternate)
Shri M. C. Goel
Shri V. L. Venkataraman
Shri P. Adinarayana (Alternate)
(Continued on page 28)
27
IS 7634 (Part 3) : 2003
(Continued from page 27)
Organization
Directorate Genera! of Supplies and Disposals, Kolkata/New Delhi
Fmolex Industries Limited, Pune
Jain Irrigation Systems Limited, Jalgaon
Mahanagar Telephone Nigam Limited, New Delhi
National Organic Chemical Industries Limited, Thane
Reliance Industries Limited, Mumbai
Rex Polyextrusion Limited, Sangli
RITES, New Delhi
Supreme Industries, Jalgaon
Tamil Nadu Water Supply and Drainage Board, Chennai
Tamil Nadu Water Supply and Sewage Board, Chennai
Telecommunications Consultants India Limited, New Delhi
In personal capacity (C-478B, Sushant Lok Phase 1, Gurgaori)
in personal capacity (196 Gulmohar Park, New Delhi 1 10 049)
Representative(s)
Shri Rajender Prasad
Shri N. K. Kaushal (Alternate)
Dr Dhananjay Rau
Shri V. V. Kandekar (Alternate)
Shrj S. Narayanaswamy
Shri L. Jagannathan (Alternate)
Shri S. K. Chadha
Shri M. K. Singhal (Alternate)
Shri P. K. Bhatia
Shri M. M. Shah (Alternate)
Dr S. M. Diwan
Shri M. V. Prasad (Alternate)
Shri Chandersekhar
Shri C K. Sharma
Deputy Chief Inspector Engineer (Alternate)
Shri W. Mandonca
Shri G. K. Saxena (Alternate)
Engineer-in-Chief
Joint Chief Engineer (Material) (Alternate)
Shri P. M. Harinath
Deputy Director (CR) (Alternate)
Shri S. N. Jha
Shri M. K. Srivastava (Alternate)
Shri O. P. Ratra
Shri Kanwar A. Singh
28
Bureau oflndian Standards
BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promote
harmonious development of the activities of standardization, marking and quality certification of goods
and attending to connected matters in the country.
Copyright
BIS has the copyright of all its publications. No part of these publications may be reproduced in any form
without the prior permission in writing of BIS. This does not preclude the free use, in the course of
implementing the standard, of necessary details, such as symbols and sizes, type or grade designations.
Knquiries relating to copyright be addressed to the Director (Publications), BIS.
Review of Indian Standards
Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed
periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are
needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards
should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of
'BIS Catalogue' and 'Standards: Monthly Additions'.
This Indian Standard has been developed from Doc : No. CED 50 (5930).
Amendments Issued Since Publication
Amend No.
Date of Issue
Text Affected
BUREAU OF INDIAN STANDARDS
Headquarters :
Manak Bhavan, 9 Bahadur Shah Zafar Marg, New Delhi 1 10 002
Telephones : 2323 0131, 2323 33 75, 2323 9402
Regional Offices :
Central
Eastern
Manak Bhavan, 9 Bahadur Shah Zafar Marg
NEW DELHI 110 002
1/14 C.I.T. Scheme VII M, V. I. P. Road, Kankurgachi
KOLKATA 700 054
Northern : SCO 335-336, Sector 34-A, CHANDIGARH 160 022
Southern : C.I.T. Campus, IV Cross Road, CHENNA1 600 1 13
Western
Branches
Manakalaya, E9 MIDC, Marol, Andheri (East)
MUMBAI 400 093
Telegrams : Manaksanstha
(Common to all offices)
Telephone
J 2323 7617
\ 2323 3841
("2337 8499,2337 8561
12337 8626,2337 9120
{
60 3843
60 9285
J2254 1216,2254 1442
\_2254 2519, 2254 2315
J~2832 9295, 2832 7858
\2832 7891, 2832 7892
AHMEDABAD. BANGALORE. BHOPAL. BHUBANESHWAR. COIMBATORE. FARIDABAD.
GHAZ1ABAD. GUWAHATI. HYDERABAD. JAIPUR. KANPUR. LUCKNOW. NAGPUR.
NALAGARH. PATNA. PUNE. RAJKOT. THIRUVANANTHAPURAM. VISAKHAPATNAM.
Printed at Prabhat Offset Press, New Delhi-2
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